EV4021A-S-00D Universal input, 24W Primary-side-control with Active PFC T8 Isolated LED Driver Evaluation Board

Transcription

1 EV4021A-S-00D Universal input, 24W Primary-side-control with Active PFC T8 Isolated LED Driver Evaluation Board DESCRIPTION The EV4021A-S-00D Evaluation Board is designed for driving a nominal LED string voltage of 38V at 0.6A from universal input (90VAC-265VAC). The LED driver uses the MP4021A. The MP4021A is a primary-side-control offline LED lighting controller which can achieve high power factor and accurate LED current for an isolate lighting application in a single stage converter. It works in boundary conduction mode for reducing the MOSFET and Diode switching losses. The EV4021A-S-00D has a low profile and high efficiency, and meets IEC61547 surge immunity (Line to Line 500V), IEC Class C harmonics and EN55015 conducted EMI requirements. It has multi-protection function such as over-voltage protection, short-circuit protection, cycle by cycle current limit, etc. ELECTRICAL SPECIFICATION Parameter Symbol Value Units Input Voltage V IN VAC Output Voltage V OUT 38 V LED Current I LED 600 ma Output Power P OUT 24 W Efficiency (full load) η >85 % Power Factor >0.9 THD <20 % FEATURES Low profile design, <10mm component height Unique architecture for superior line regulation High power factor>0.9 over universal input voltage Boundary conduction mode improves efficiency Cycle-by-cycle current limit Over-voltage protection (OVP) Short-circuit protection (SCP) Fit inside T8 tube enclosure APPLICATIONS T8 Tube Replacement Solid State Lighting Industrial & Commercial Lighting Residential Lighting All MPS parts are lead-free and adhere to the RoHS directive. For MPS green status, please visit MPS website under Quality Assurance. MPS and The Future of Analog IC Technology, are Registered Trademarks of Monolithic Power Systems, Inc. Warning: Although this board is designed to satisfy safety requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. EV4021A-S-00D Rev

2 EV4021A-S-00D EVALUATION BOARD Board Number EV4021A-S-00D MPS IC Number MP4021GS-A EVALUATION BOARD SCHEMATIC Figure1 Schematic EV4021A-S-00D Rev

3 PRINTED CIRCUIT BOARD LAYOUT Figure 2 Top Layer Figure 3 Bottom Layer EV4021A-S-00D Rev

4 CIRCUIT DESCRIPTION The EV4021A-S-00D is configured in a singlestage Flyback topology, it uses primary-sidecontrol which can mostly simplify the schematic and get a cost effective BOM. It can also achieve high power factor and accurate LED current. F1, CX1, L1, L2, L3, C1 and BD1 compose the input stage. F1 fuses the AC input to protect for the component failure or some excessive short events. CX1, L1, L2, L3 and R3 associated with CY1 and L4 form the EMI filter which can meet the requirement for universal input. The diode rectifier BD1 rectifies the input line voltage. Small bulk CBB capacitor C1 is used for a low impedance path for the primary switching current, to maintain high power factor, the capacitance of C1 should be selected with low value. R4A, R4B, R5, C2 provide sine wave reference for the primary peak current to get an active PFC function. The divided voltage should be lower than the max voltage rating of MULT pin. R6A, R6B, C3, C4, D1, R7, D2 are used to supply the power for MP4021A. A 10μF bulk capacitor C3 is selected to maintain the supply voltage. The small decoupling cap C4 is used for reducing the noise. Zener diode D1 is used to clamp the max voltage for VCC at OVP condition. At start-up, C3 is first charged up by the start resistor R6A and R6B from the line voltage, when the VCC voltage passes the UVLO threshold the IC starts to work and the gate begins to switch, then the VCC power supply is taken over by the auxiliary winding through R7, D2. R17, R18, D4, C7 are used to detect the auxiliary winding to get the transformer magnetizing current zero crossing signal for realizing the boundary conduction operation, and also monitor the output OVP condition. The OVP voltage is set by the divider ratio of R17, R18. D4, C7 are used to reduce the noise by clamping the negative voltage and decoupling the high frequency du/dt influence on ZCD pin. R8, R9, D5 are used to monitor the OCP condition. The primary-side OCP point is set by the forward voltage of D5 and the divider ratio of R8 and R9. R13, R14, R16 are primary sensing resistors for primary side current control. The value of R13, R14 and R16 sets the output LED current. R10A, R10B and R12 form a feedforward from input line voltage to optimize the line regulation. C6, R15, D3 are used to damp the leakage inductance energy so the drain voltage can be suppressed at a safe level. Diode D6 rectifies the secondary winding voltage and the capacitor C9, C10 are the output filter. The resistor R2 is placed as pre-load to limit the output voltage rise too high in open load condition. EV4021A-S-00D Rev

5 EV4021A-S-00D BILL OF MATERIALS Qty Ref Value Description Package Manufacture Manufacture_PN 1 BD1 DF06S Diode;600V;1A SMD Fairchild DF06S 1 C1 220nF Capacitor;400V;CBB DIP Panasonic ECQE4224KF 2 C2, Ceramic Capacitor; 100pF C4 50V; Murata GRM1885C1H101JA01 1 C3 10μF Electrolytic Capacitor;50V; DIP Jianghai CD287-50V10 1 C5 2.2μF Ceramic Capacitor; 16V;X5R; TDK C2012X5R1C225K 1 C6 10nF Ceramic Capacitor; 630V;COG;X7R;1206; 1206 TDK C3216X7R2J103K 1 C7 22pF Ceramic Capacitor; 50V; TDK C1608C0G1H220D 1 C8 68pF Ceramic Capacitor; GRM31A7U2J680JW Murata 630V;COG;X7R;1206; D 2 C9, C10 330μF Electrolytic Capacitor;63V; DIP Jianghai CD263-63V330 1 CX1 0.1μF Film Capacitor;275V;10% DIP Carli PX104K3ID19L270D9R 1 CY1 2.2nF Y Capacitor;4000VAC DIP hongke JNK12E222MY02N 1 D1 BZT52C20 Zener Diode;20V; 2mA/500mW; SOD-123 Diodes BZT52C20 1 D2 ES1D Diode;200V;1A; SMA Taiwan semi ES1D 1 D3 1N4007 Diode;1000V;1A DO-41 Diodes 1N D4, D5 1N4148W Diode;75V;0.15A; SOD-123 Diodes 1N4148W 1 D6 UF3004 Diode;400V;3A DO- 201AD 1 F1 250V SS-5-2A DIP Diodes COOPER BUSSMANN UF3004 SS-5-2A 2 L1,L4 600μH Common Inductor; 600μH DIP Emei TP4U L2 60mH Common Inductor; 60mH DIP OEMA 1 L3 2.2mH Inductor;2.2mH;0.5A DIP OEMA 1 Q1 SMK0870F Mosfet;700V;8A TO-220F AUK SMK0870F 3 R1, R10A, R10B 5.1MΩ Film Resistor;1%;1/4W 1206 Yageo RC1206FR-075M1L 1 R2 30kΩ Film Resistor;1%;1/4W 1206 Yageo RC1206FR-0730KL 1 R3 5.1kΩ Film Resistor;1%;1/4W 1206 Yageo RC1206FR-075K1L 3 R4A, R4B, R15 499kΩ Film Resistor;1%;1/4W 1206 Yageo RC1206FR-07499KL 1 R5 8.2kΩ Film Resistor;1%;1/10W 0603 Yageo RC0603FR-078K2L 2 R6A, R6B 300kΩ Film Resistor;1%;1/4W 1206 Yageo RC1206FR-07300KL 1 R7 20Ω Film Resistor;1%;1/4W 1206 Yageo RC1206FR-0720RL 1 R8 487Ω Film Resistor;1%;1/10W 0603 Yageo RC0603FR-07487RL 1 R9 330Ω Film Resistor;1%;1/10W 0603 Yageo RC0603FR-07330RL 1 R11 20Ω Film Resistor;1%;1/8W 0805 Yageo RC0805FR-0720RL EV4021A-S-00D Rev

6 EV4021A-S-00D BILL OF MATERIALS (continued) Qty Ref Value Description Package Manufacture Manufacture_PN 1 R12 200Ω Film Resistor;1%;1/10W 0603 Yageo RC0603FR-07200RL 2 R13, R14 1.8Ω Film Resistor;1%;1/4W 1206 Yageo RC1206FR-071R8L 1 R16 0.2Ω Film Resistor;1%;1/4W 1206 Yageo RC1206FR-070R2L 1 R17 11kΩ Film Resistor;1%;1/10W 0603 Yageo RC0603FR-0711KL 1 R18 36kΩ Film Resistor;1%;1/8W 0805 Yageo RC0805FR-0736KL 1 R19 100Ω Film Resistor;1%;1/4W 1206 Yageo RC1206FR-07100RL 1 RV1 TVR10431KSY MOV;430V DIP TKS TVR10431KSY 1 T1 Np:Ns:Naux =36:9:4; Transformer EDR3909 DIP OEMA FX0289 Lp=0.85mH 1 U1 MP4021A LED Controller SOIC8 MPS MP4021A EV4021A-S-00D Rev

7 Electric Strength Test Primary circuit to secondary circuit electric strength testing was completed according to IEC and IEC Input and output was shorted respectively. 3750VAC/50Hz sine wave applied between input and output for 1min, and operation was verified. Surge Test Line to Line 500V surge testing was completed according to IEC Input voltage was set at 230VAC/50Hz. Output was loaded at full load and operation was verified following each surge event. Surge Level (V) Input Voltage (VAC) Injection Location Injection Phase ( ) Test Result (Pass/Fail) L to N 90 Pass L to N 270 Pass EV4021A-S-00D Rev

8 EVB TEST RESULTS Performance waveforms are tested on the evaluation board. 11 LEDs in series, I LED =600mA, V OUT =38V. EV4021A-S-00D Rev

9 EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. V AC =110V/60Hz, 11 LEDs in series, I LED =600mA, V OUT =38V. EV4021A-S-00D Rev

10 EVB TEST RESULTS (continued) Performance waveforms are tested on the evaluation board. V AC =220V/50Hz, 11 LEDs in series, I LED =600mA, V OUT =38V EV4021A-S-00D Rev

11 QUICK START GUIDE 1. Preset AC Power Supply to 90V V AC 265V. 2. Turn Power Supply off. 3. Connect the LED string between LED+ (anode of LED string) and LED- (cathode of LED string). 4. Connect Power Supply terminals to AC input terminals, L & N, as shown on the board. 5. Turn AC Power Supply on after making connections. EV4021A-S-00D Rev

12 APPENDIX1: TRANSFORMER SPECIFICATION Electrical Diagram N1 N2 N3 6 8 Tapes:1T Tapes:1T Tapes:1T N3 N2 N1 Winding Start Teflon Tub Pri Sec 1 2 Pin Definition of Bobbin Pin out copper Note: use a copper wire to connect copper with pin 4 of bobbin View from the top Winding Diagram 7 6 Table 1 Electrical Characteristic Parameter Condition Value Primary Inductance L(3-1) 0.85mH±5% Core EDR3909 Bobbin Core Material EDR3909 DMR40 or equivalent Turn Ratio N1:N2:N3 36:4:9 Tape Turns Winding No. Table 2 Winding Specification Margin Tapes Start& End Wire Diameter (mm) Turns 1 N N N TIW 1 9 NOTICE: The information in this document is subject to change without notice. Please contact MPS for current specifications. Users should warrant and guarantee that third party Intellectual Property rights are not infringed upon when integrating MPS products into any application. MPS will not assume any legal responsibility for any said applications. EV4021A-S-00D Rev